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ICP PGAA, PGME, PGAC, PGAD, PGMD Installation Instructions Manual

Installation Instructions
I PGAA / PGAC / PGAD - 11/2 to 5 TON
PGMD/PGME
COMBINATIONUNITS
GASHEAT/ELECTRICCOOL
TABLEOFCONTENTS
1. SAFETY LABELING AND SIGNAL WORDS .................... 2
SignalWordsinManuals........................................ 2
DangerLabel ................................................ 2
WarningLabel ............................................... 2
CautionLabel................................................ 2
2. UNIT DIMENSIONS ..................................... 3-4
3. SAFE INSTALLATION REQUIREMENTS ...................... 5
4. LOCATING THE UNIT .................................... 5
MinimumClearancesto CombustibleConstruction...................... 5
ROOFTOPINSTALLATION...................................... 5-6
HeatingVentAssembly ......................................... 6
CondensateDrain ............................................. 6
5. PRE- EXISTING COMMON VENT CHECK ...................... 7
6. GAS SUPPLY AND PIPING ................................ 7
GasPipeSize ............................................... 7
Connections................................................. 7
OrificeSizes ................................................. 7
ChangingOrifices ............................................. 8
7. ELECTRICAL WIRING .................................... 8
UneVoltageWiring ............................................ 8
GroundConnections ........................................... 8
UneConnections .............................................8
THERMOSTAT/HEAT ANTICIPATOR ...............................8
FinalElectricalCheck .......................................... 8
8. DUCTWORK ........................................... 8
DuctworkInsulation ........................................ 9
DuctworkConnections.......................................... 9
FILTERS ..................................................... 9
9. START- UP PROCEDURES ................................ 9
CHECKBEFORESTARTING ...................................... 9
ReverseRotation(ScrollCompressorsOnly) .......................... 9
ManifoldGas PressureAdjustment ................................. 9
GASPRESSURES.............................................. 9
CIRCULATINGAIRBLOWER ..................................... 10
HEATINGSTAR-UPPROCEDURES................................ 10
TemperatureRiseCheck ....................................... 10
FANCONTROLCHECK ......................................... 10
SPEEDTAPS ................................................. 11
CONTINUOUSFANOPERATION .................................. 11
COOLING ................................................... 11
10. OPERATION ......................................... 12
COMBUSTIONIINDOORFANCONTROL............................. 12
SCROLLANTI-CYCLETIMER .................................... 12
11. MAINTENANCE ....................................... 12
MONTHLYMAINTENANCEANDINSPECTIONCHECKS ................. 12
Air Filters .................................................. 12
HEATINGSEASONCHECKS (MONTHLY) ........................... 12
Pilot Flame ................................................. 12
MainBurnerFlame ........................................... 12
ANNUALMAINTENANCEANDINSPECTION ......................... "12
CondenserFan Motor ......................................... 12
VENTASSEMBLY ............................................. 13
BLOWERMOTORACCESS ...................................... 13
Method1 .................................................. 13
Motorremovalandreplacement.................................. 13
Method2 .................................................. 13
Burners/ HeatExchangers/ FlueGas Passages ...................... t3
INSPECTIONANDCLEANINGOF BURNERASSEMBLY
/HEATEXCHANGERS/FLUEGASPASSAGES..................... 13-14
ForOaaiifiedServiceTechnicianOnly ........................... t3-t4
12. RIGGING INSTRUCTIONS .............................. 15
13. NOTES ............................................. 16
462 01 1004 00
10-23-01
Printed in U.S.A.
1. Safety Labeling and Signal Words
Danger, Warning and Caution
ThesignalwordsDANGER,WARNINGandCAUTIONareusedtoidentifylevelsofhaz- ard seriousness.The signalword DANGERis onlyusedon productlabelsto signifyan immediatehazard.The signalwordsWARNINGandCAUTIONwillbe used onproduct
labelsandthroughoutthis manualandothermanualsthat mayapplyto theproduct.
Danger Label Whiteletteringonablackbackgroundexceptthe wordDANGERwhichiswhitewitha red
background.
Signal Words
DANGER- ImmediatehazardswhichWILLresultin severepersonalinjuryordeath. WARNING- HazardsorunsafepracticeswhichCOULDresultinseverepersonalinjuryor
death. CAUTION- HazardsorunsafepracticeswhichCOULDresultinminorpersonalinjuryor
productor propertydamage.
Warning Label Whiteletteringon ablackbackgroundexceptthe wordWARNINGwhichisblackwithan
orangebackground.
Signal Words in Manuals Thesignal wordWARNINGisusedthroughoutthismanualinthefollowingmanner:
Thesignal wordCAUTIONisusedthroughoutthismanualin thefollowingmanner:
CAUTION
Product Labeling
Signalwords areusedin combinationwithcolors and/orpictureson productlabels.Fol- lowingareexamplesof productlabelswith explanationsofthe colors used.
Caution Label Whiteletteringon a blackbackgroundexceptthe wordCAUTIONwhichisblackwitha
yellowbackground.
2. Unit Dimensions "B" CHASSIS UNIT DIMENSIONS
COMBINATION GAS/
A B C D
E
F
G
H I J
K
L M N
P
Q
R
S
D01_<
A B C
D E F G H K*
Units in "B" Chassis Configuration
PGAA18-42
ELECTRIC UNITS
"B" Chassis PGAC36-42 _ A
(473/8x473/8) PGAD24-36_ _ _ _"B"
INCHES MILLI_IETER "C" /__
32-1/2I 828
47-3/8 I 1203 / / (- _((_,(_..(_)_J))))))))]/ _. _.
47-378 I 1203 / / _ _._.___/JJJ _ "%1
3-1/8 I 79 / / ___/ _ /"
11-1/8 I 283 _ _ _/
12 I 306 _ //
14-1/4 I 363 _ // 14-1/4 I 363 _ //
12 I 306 __ _ _ "A"
4 102 'T'/"
4-1/4 to8 _ _ "E'_
12-1/4 311 // \_Xj _ _/'_ / _ -
12-118 308 / / 'D" // 'H" -"_/, / 14-1/4 363 / / y _ _O_
I
12-1/4 318
t&5)_> _._ _ ,,,
I-1/2'_
(539.75) _ } "",_ '_L"<,..,._ / _ _.. /_ \
11-1/8" _ 4"_
UNBT NAgN NHOWN 8NPARATNLY _
ROOFCURB TO ILLUSTRATE BOTTOM
for units in #UOT OPSN_I8
"B" Chassis
(473/8 x 473/8) Units in "B" Chassis Configuration_
"NCHES M,LI=IM_T_.8 PGAA18-42 _ _.
42-3/4 1086 PGAC36-42 _
3-3/4
42-3/4 1086 _ _ _ _
14 356
80-10-12
7_ROOF CU_E_S ARE ALSO AVA_LAE_LE I_ 8"(203} AND 24"(610) HEIGHTS (K D_MENSION).
"C" CHASSIS UNIT DIMENSIONS
1-1/2"
COMBINATION GAS/
ELECTRIC UNITS
"C" Chassis
(473/8 X 73)
DgM. INCHES MILLIMETER8
A 36 914
B 47-3/8 t 203
C 73 1354
D 4-5/8 117 E 15 361 F 12 307
G 18-3/4 476
H 18-3/4 476 I 12 306
J 4 t02
K 1 & 1-1/4 25 & 31 L 4-1/4 108 M 5-1/4 133 N 12-1/4 311
P 19 483
Q 15 381
R 19 483 S 12-1/4 318 T 16-7/8 429
ROOF CURB
for
"C" Chassis
(473/8 X 73)
#_M. "NCHE8 M_LL_METER8
A 67-3/4 1721
B 64-3/4 1645 C 23 584
D 23 584
E 2-1/2 64
F 42-3/4 1086 G 39-3/4 1010
H 23 584
I 12 305 J 12 305
K* 14 356
(10t.8)
ELECTRICAL POWER
CONDUIT ('K' DIM.)
VOLTAGE
1/2" (12.7) CONDUIT
GAS CONNECTION
_/2" (12,7) P_PE
Units in "C" Chassis Configuration
PGAA48-60 PGAC48-60 PGAD42-60
UNIT BASE SHOWN SEPARAT
TO ILLUSTRATE BOTTOM DUCT OPENINGS
"F\
-/_-ROOF CURBS ARE ALSO AVAILABLE IN 8"(208) AND 24"(810) HEIGHTS (K DIMENSION),
80-18-11
3. SAFE INSTALLATION REQUIREMENTS
Installation or repairs made by unqualified persons can result
in hazards to you and others. Installation MUST conform with local building codes or, in the absence of local codes, with the
ANSI Z223.1 and the National Electrical Code NFPA70-f 990 or in Canada the National Standard CANiCGA B149-1 and CSA
C.22.1 - Canadian Electrical Code Part 1.
The information contained in this manual is intended for use by a qualified service technician familiar with safety proce-
dures and equipped with the proper tools and test instru- ments.
Failure to carefully read and follow all instructions in this
manual can result in furnace malfunction, property damage, personal injury and/or death.
• DoNOT usethisfurnaceas aconstructionheater.
• Useonlythe Typeofgas approvedforthis furnace(SeeRatingPlate).
• DoNOT useopen flameto testfor gas leak.
• Sealsupplyand returnair ducts.
• Checkto seethat filtersareinstalledcorrectlyandarethepropertypeandsize.
NOTE:It isthepersonalresponsibilityandobligationofthecustomertocontacta qualified installerto ensurethat theinstallationisadequateandconformsto governingcodesand
ordinances.
CAUTION
It is recommended that a qualified service technician check the heat exchanger integrity every two (2) years, after the first four (4) years of operation.
4. LOCATING THE UNIT
ACCESS PANELS See FIGURE1forageneralviewofunitandlocationofaccesspanels.
Carbon monoxide poisoning hazard.
Do NOTinstalltheunit in alocationthatwillpermitdischargedairfromthecondenserto recirculatetothe condenserinlet.
CAUTION
Do NOT operate unit in a corrosive atmosphere containing chlorine, fluorine, or any other corrosive chemicals.
Minimum Clearances to Combustible Construction
Furnace Plenum ........................................... 2"
Duct Side ........................ 2" (6" on large chassis models)
Condenser Inlet Side ...................................... 30"
Blower Service (Rear) ..................................... 30"
Control Service Side
(Front Combustion Air Inlet) ................... 30"
Clearance between 3 Ft. Overhang
and Top of Unit .............................. 30"
Combustible Base
(Wood or Class A, B or C
roof covering material) ......................... 0"
FIGURE 1
\
I Minimum Clearances and Access Panels
(B Chassis Shown)
Blower Compartment Panel
I nternal Filter Access
from Burner Compartment Side 26" (C Chassis Units)
30"
80-00-01
Burner Compartment
Panel
Keep blower door closed.
Failure to keep blower door closed can result in bodily injury
and/or death.
CLEARANCES
ThelocationMUSTallowfor minimumclearancesandshouldnot beadjacentto apatioor otherareawheretheunit'soperatingsoundlevelmightbeobjectionable.Thecombustion airinletopeningsMUSTnotbeobstructed(seeFIGURE1).In addition,localcodesMUST
beobserved. NOTE:Units withbuiltinfilterracks( "C" Chassis48x 73 models),need a26" minimum
clearanceatfrontofunitforremovaloffilters.Seechartbelowif unitisgoingtobe placed nearcombustibleconstructionormaterials.
While minimumclearancesare acceptablefor safetyreasons,they may notallowade- quateair circulationaroundthe unitfor properoperationinthecoolingmode.Whenever
possible,itisdesirabletoallowadditionalclearance,especiallyaroundthecondenserinlet anddischargeopenings.
INSTALLATION
NOTICE
Unit will NOT operate properly unless it is installed level front to rear and side to side.
The slope MUST NOT be greater than 1/8" per foot (10mm per meter). For side to side leveling, the drain side MUST always be lower.
Ground Level Installation
Groundlevel platformrequirements:
- The unitMUSTbe situatedtoprovidesafo accessforservicing. Platformmay be madeof eitherconcreteor pressuretreatedwoodand MUSTbe
level andstrongenoughto supportunitweight. Positionplatformseparatefrom buildingfoundation.
Installin well-drainedarea,withtopsurface ofplatformabovegrade level. Platformmust be highenoughto allowfor propercondensatetrapinstallationand
drainage.SeeFIGURE4 andassociatedtextfor moreinformationaboutconden- satedrainage.
Rooftop Installation Rooftopplatformrequirements:
- The unitMUST be situatedto providesafoaccessforservicing.
- TheexistingroofstructureMUSTbeadequatetosupporttheweightoftheunitorthe
roofMUSTbereinforced.
Checktheweightoftheunitin relationtothe roofstructureandlocalbuildingcodes orordinancesand reinforceroofstructureifnecessary.See FIGURE21onthe back
coverofthis manualforunit weights.
- Supportfortheunit MUSTbelevelandstrongenoughtocarryunitweight.Thesup- portmayconsistof aplatformoracombinationof platformand roofbeamsorcurb.
- See Hoistingsectionbelowfor hoistinginstructions.
HOISTING
NOTE:All accesspanelsMUST besecuredin placebeforehoisting. Theunitshouldbe hoistedwithtwo liftingslings.Attachtheslingsto riggingshacklesthat
havebeen hookedthroughholesin the baserail. TwospreaderbarsMUSTbeplacedontop ofthe unitto protecttheunitfromdamagefrom
thepressureexertedbythe slings.Makesurethatallequipmentisadequatetohandlethe weightofthe unit andthatthe slingswill not allowthe unitto shift.
RefertoFIGURE21on thebackcoverof thismanualforillustratedrigginginstructionsand weightchart.
DOWNFLOW CONVERSION
These unitsare adaptableto downflowuse. Toconvert to downflowuse,follow these steps:
1. Removethe blockoffplatesfoundin the returnaircempartmentandthe supplyair compartment.SeeFIGURE2.
NOTE:Blockoffplateinthesupplyaircempartmentonlycontainsonescrew.Ifreinstalling plate,backpartofplateMUSTfitintomatingdimplesonflange.Toreinstall,slantplateinto dimples,thenput plate intopositionand fastenwithscrew.
2. Instanthe removedplateson thehorizontalreturnand supplyair openings.
3. Installroofcurb on the building.Besure to followall directionsincludedwithcurb andallapplicablebuildingcodesinyourinstallation.(SeePages2 or3forappropri- atecurbto usewithyour model.)
FIGURE 2 Blockoff Plate (Return Air Compartment)
I
FIGURE 3 l Heating Vent Assembly
Flue Support
(Shipped mounted to unit
Flue Cover
\
CAUTION
DO NOT OPERATE THE UNIT WITHOUT THE VENT ASSEMBLY INSTALLED
Condensate Drain Thecondensatedrainoutletisa 3/4"(19.1mm)threadedfemalePVCconnectionlocated
atthe bottomofthe unittotherightofthe filteraccesspanel(see FIGURE4).Condensate drainoutletMUSTbe heldwith wrenchwheninstallingtrapand drainline.
Thecirculatingblowercreatesa negativepressureonthe condensatedrainline thatcan preventthe condensatefromdrainingproperly.Tocombatthis negativepressure,a field
suppliedcondensatetrapthatwillallowastandingcolumnofwaterofat least2" (50.8mm) MUSTbe installed. Topofoutletfromtrap MUSTbeat least1" (25.4mm)belowtopof outletfromunit.Install the trapas nearto the unit aspossiblefor properdrainage.
A3/4"(19.1mm)drainlineMUSTbeinstalledif requiredbylocalcodesoriflocationofunit requiresit.Runthedrainline toan opendrainorothersuitabledisposalpoint.
I Condensate Drain Information*
FIGURE 4
A
25-1/2 ("B" Chassis) 32-1/4 ("C" Chassis)
3/4" (19.1mm) Threaded Female
PVC Fitting
I r,
(25.4mm)
2" (50.8mm)
Heating Vent Assembly
Thefluecover ispackedwithscrewsinthereturnaircompartment.RefertoFIGURE3and assembleas shown.
* Condensate trap MUST be installed.
5. PRE-EXISTING COMMON VENT CHECK
Iftheinstallationofthecombinationunitinvolvesremovinganexistingfurnacefromacom- monventwithother appliances,the existingventingsystemwillprobably betoo largefor the remainingappliancesand they willnotvent properly.The existingventingsystem MUSTbe checkedby a qualifiedtechnicianto ensureit isproperlysizedand
ventsproperly.
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